Mercedes-Benz 2005 Sprinter Manuals

Mercedes-Benz 2005 Sprinter Manuals

Manuals and User Guides for Mercedes-Benz 2005 Sprinter. We have 1 Mercedes-Benz 2005 Sprinter manual available for free PDF download: Service Manual

Mercedes-Benz 2005 Sprinter Service Manual

Mercedes-Benz 2005 Sprinter Service Manual (1233 pages)

Brand: Mercedes-Benz | Category: Automobile | Size: 41.13 MB

Table of Contents

Group Tab Locator
1
Description
3
Table of Contents
3
Vehicle Identification Number
3
Vin Decoding Information
3
Fastener Identification
4
International Control and Display Symbols
4
International Symbols
4
Number
4
Bolt Markings and Torque Values
5
Bolt Markings and Torque - Metric
5
How to Determine Bolt Strength
6
Conversion Formulas and Equivalent Values
7
Fastener Usage
7
Metric System
7
Threaded Hole Repair
7
Specified Torque for Standard Bolts
9
Torque References
9
Table of Contents
11
Lubrication & Maintenance
11
Description - Engine Coolant
11
Fluid Types
11
Description - Fuel Requirements - Diesel Engine
11
Fluid Types

12
- Coolant Performance
  12
- Description - Hoat Coolant
  12
Fluid Capacities

14
- Specifications - Fluid Capacities
  14
Fluid Types

14
Fluid Fill/Check Locations

14
- Inspection - Fluid Fill/Check
  14
- Floor Jack
  15
Parts & Lubricant Recommendation Standard Procedure - Parts & Lubricant Recommendations

15
- Standard Procedure - Hoisting
  15
- Suspension
  15
Jump Starting

16
- Standard Procedure - Jump Starting
  16
  - To Jump Start a Disabled Vehicle:
    16
  - Ground Clearance
    17
Maintenance Schedules Description

17
- Ramp Angle
  17
- Safety Precautions
  17
- Engine Oil Change and Filter Replacement
  18
- Maintenance - with Assyst Maintenance Computer
  18
- Number
  18
- Regular Check-Ups
  18
- Special Maintenance Requirements
  18
- Additional Maintenance Work
  19
- Additional Maintenance Work after Years
  19
International Symbols Description

19
- Suspension
  21
- Front Suspension
  22
- Special Tool Cross Reference Chart
  22
- Special Tools Front Suspension
  22
- Specifications - Torque Chart
  22
  - Ball Joint Separator
    23
  - Installation
    23
    
    Lca Bushing Removal
    23
    
    Leaf Spring Wedge Block
    23
  - Diagnosis and Testing
    24
  - Front Wheel Hub with Single Rear Wheels (Srw)
    24
  - Hub / Bearing
    24
    
    Lca Bushing Install
    24
    
    Measuring & Adjusting Wheel Bearing
    24
  - Removal
    24
  - Front Wheel Hub with Dual Rear Wheels (Drw)
    25
  - Installation
    25
  - Knuckle Removal
    25
  - Steering Knuckle
    25
  - Front
    26
  - Installation
    26
  - Lower Ball Joint Removal
    26
  - Lower Control Arm Removal
    26
  - Spring Removal
    27
  - Front Spring
    28
  - Installation
    28
  - Spring Clamp Plates Removal
    28
  - Installation
    29
  - Operation
    29
  - Removal
    29
  - Spring Stop Plates Removal
    29
  - Stabilizer Bar Description
    29
  - Stabilizer Link
    29
  - Strut Installation
    30
  - Strut Removal
    30
    
    Diagnosis and Testing - Spring and Shock
    31
    
    Rear
    31
  - Rear Description
    32
  - Specifications - Torque Chart
    32
  - Spring and Shock Absorber
    32
  - Diagnosis and Testing - Shock
    33
Shock

33
- Installation
  33
- Removal
  33
- Shock Absorber
  33
- Spring Description
  34
  - Installation Installation - (Srw)
    34
  - Rear
    34
  - Removal - (Drw)
    34
  - Removal Removal - (Srw)
    34
    
    Spring Installation
    34
    
    Spring Operation
    34
    
    Spring Removal
    34
  - Installation
    35
  - Installation - (Drw)
    35
  - Spring Shackle Removal
    35
  - Stabilizer Bar Removal
    35
  - Stabilizer Link Installation
    36
  - Stabilizer Link Removal
    36
    
    Diagnosis and Testing - Pre-Alignment Inspection
    37
    
    Wheel Alignment
    37
    
    Wheel Alignment Measurements
    37
    
    Suspension and Steering System Diagnosis
    38
    
    Front Specifications
    39
    
    Rear Specifications
    39
    
    Standard Procedure - Toe Adjustment
    39
    
    Differential & Driveline
    41
    
    Propeller Shaft
    41
    
    Driveline Vibration
    42
    
    Propeller Shaft Balance
    42
    
    Clamp Screw
    43
    
    Propeller Shaft Angle
    43
    
    Propeller Shaft Runout
    43
    
    Runout Specifications
    43
  - Standard Procedure
    43
    
    Two/Three-Piece Propeller Shaft
    44
    
    Universal Joint Angle Example
    44
    
    Special Tool Cross-Reference Chart
    45
  - Specifications
    45
Propeller Shaft

46
- Alignment Marks
  46
- Alignment Marks 3 Piece Shaft
  46
- Propeller Shaft
  46
- Propeller Shaft Removal
  46
  - Piece Propeller Shaft
    47
  - Rear Axle
    47
  - Center Bearing
    48
  - Removal
    48
  - Installation
    49
    
    Bearing Noise
    50
    
    Gear Noise
    50
    
    Rear Axle
    50
    
    Driveline Snap
    51
    
    Low Speed Knock
    51
  - Removal
    51
    
    Standard Procedure - Drain and Fill
    51
    
    Vibration
    51
  - Installation
    52
    
    Single Rear Wheel Axle
    52
    
    Axle Specifications
    53
    
    Dual Rear Wheel Axle
    53
  - Special Tools
    54
  - Axle Shafts
    55
  - Installation
    55
  - Removal
    55
Axle Shafts

55
- Axle Shaft and Tube
  56
- Bearing Cap Bolts
  56
- Rear Axle
  56
  - Axle Bearings/Seals Removal
    57
  - Bearing Nut and Locking Ring
    57
  - Installation
    57
  - Bearing Nut Wrench
    57
  - Locking Ring
    57
  - Axle Shaft Assembly
    58
  - Bearings and Race
    58
  - Pressing Bearing
    58
  - Seal Installer
    58
- Axle Shafts - Dual Rear Wheels
  59
  - Bearing and Shaft
    59
  - Installation
    59
  - Pressing Axle Shaft
    59
  - Removal
    59
  - Axle Hub Bearings/Seals
    60
  - Hub Nuts
    60
  - Installation
    60
  - Removal
    60
    
    Inner Hub Nut
    61
    
    Locking Plate
    61
    
    Outer Hub Bearing
    61
    
    Thrust Washer
    61
    
    Collared Nut
    62
    
    Flange Puller
    62
  - Installation
    62
  - Pinion Seal Removal
    62
    
    Bend Collar of Nut
    63
    
    Fill Plug
    63
    
    Pinion Seal Installer
    63
    
    Brakes
    65
  - Diagnosis and Testing - Base Brake System
    66
Brakes - Base

66
- Brakes - Base
  66
  - Preliminary Brake Check
    66
  - Low Pedal
    67
  - Pedal Falls Away
    67
  - Road Testing
    67
  - Spongy Pedal
    67
  - Brake Chatter
    68
  - Brake Noises
    68
  - Brake Squeak/Squeal
    68
- Standard Procedure - Manual
  68
  - Standard Procedure
    68
    
    Thump/Clunk Noise
    68
    
    Bleed Hose Setup
    69
    
    Hydraulic/Mechanical
    69
  - Specifications - Torque Chart
    69
  - Standard Procedure - Pressure Bleeding
    69
  - Base Brake
    70
  - Brakes
    71
  - Special Tools
    71
  - Brake Lines
    72
  - ISO Flaring
    72
  - Standard Procedure - Double Inverted Flaring
    72
  - Standard Procedure - Iso Flaring
    72
  - Brake Pads/Shoes
    73
    
    Front Brake Pads
    73
    
    Front Disc Brake Pads with Dual Rear Wheels
    73
  - Removal
    73
  - Removal - Front (Drw)
    73
  - Removal - Front (Srw)
    73
  - Removal - Rear (15" Wheels) (Srw)
    73
  - Removal - Rear (16" Wheels) (Srw)
    73
  - Installation
    74
  - Installation - Front (Srw)
    74
    
    Rear Disc Brake Pads - 15 Wheels
    74
    
    Rear Disc Brake Pads - 16 Wheels
    74
    
    Rear Disc Brake Pads with Dual Rear Wheels
    74
  - Removal - Rear (Drw)
    74
  - Disc Brake Calipers
    75
  - Front Disc Brake Caliper
    75
  - Installation - Front (Drw)
    75
  - Installation - Rear (16" Wheels) (Srw)
    75
  - Installation - Rear (Drw)
    75
  - Removal
    75
  - Removal - Front (Srw)
    75
  - Brakes - Base
    76
  - Disc Brake Caliper with Dual Rear Wheels
    76
  - Installation
    76
  - Installation - Front (Srw)
    76
  - Rear Disc Brake Caliper
    76
  - Removal - Front (Drw)
    76
  - Removal - Rear (Drw)
    76
  - Removal - Rear (Srw)
    76
  - Disc Brake Caliper Adapter
    77
  - Installation - Front (Drw)
    77
  - Installation - Rear (Drw)
    77
  - Installation - Rear (Srw)
    77
  - Rear Disc Brake Caliper with Dual Rear Wheels
    77
  - Removal
    77
  - Removal - Front
    77
  - Removal - Rear
    77
  - Diagnosis and Testing - Brake Fluid Contamination
    78
  - Standard Procedure - Brake Fluid Level
    78
Hydraulic/Mechanical

78
- Fluid Level Typical
  78
- Installation
  78
- Installation - Front
  78
- Installation - Rear
  78
- Specifications
  78
- Alb Controller
  79
- Alb Lever
  79
  - Alb Lever Deflection
    79
  - Fluid Reservoir Removal
    79
  - Installation
    79
  - Removal
    79
  - Adjustments Adjustment
    80
  - Alb Controller Adjuster Nut
    80
  - Diagnosis and Testing - Master
    80
  - Diagnosis and Testing - Master Cylinder/Power Booster
    80
  - Master Cylinder
    80
    
    Power Booster Check Valve Test
    81
    
    Power Booster Vacuum Test
    81
  - Removal
    81
  - Standard Procedure - Master Cylinder Bleeding
    81
    
    Vacuum Check Valve and Seal
    81
    
    Brake Pedal
    82
  - Installation
    82
  - Pedal Removal
    82
- Master Cylinder (Drw)
  82
Rotors

83
- Front Disc Brake Rotor
  84
- Front Disc Brake Rotor with Dual Rear Wheels
  84
- Rear Disc Brake Rotor
  84
- Removal - Front (Drw)
  84
- Removal - Rear (Drw)
  84
- Removal - Rear (Srw)
  84
  - Installation
    85
  - Installation - Front (Drw)
    85
  - Installation - Front (Srw)
    85
  - Installation - Rear (Drw)
    85
  - Installation - Rear (Srw)
    85
  - Rear Disc Brake Rotor with Dual Rear Wheels
    85
  - Installation - Rear
    86
  - Parking Brake
    86
  - Removal - Rear
    86
  - Specifications
    86
  - Support Plate
    86
  - Torque Chart
    86
  - Cable Tensioner
    87
  - Park Brake
    87
Parking Brake

86
- Control Cable Lock
  87
- Special Tools
  87
Cables

88
- Front Park Brake Cable at Lever
  88
- Installation
  88
- Installation - Front
  88
- Rear Park Brake Cable Remove / Install
  88
- Removal
  88
- Removal - Front
  88
- Removal - Rear
  88
  - Adjustment - Parking Brake Cables
    89
  - Installation - Rear
    89
  - Park Brake Adjuster
    89
Shoes

90
- Hand Brake Lever
  90
- Installation
  90
- Lever Removal
  90
- Park Brake Shoes
  90
- Removal
  90
- Removal - (Drw)
  90
- Removal - (Srw)
  90
  - Adjustments Adjustment
    91
  - Cleaning - Rear Drum in hat Brake
    91
  - Installation
    91
  - Installation - (Drw)
    91
  - Installation - (Srw)
    91
  - Park Brake Shoes with Dual Rear Wheels
    91
  - Adjusting Rear Park Brake Shoes
    92
  - Star Wheel Adjuster
    92
Brakes - Abs

93
- Brakes - Abs
  94
- Installation
  94
  - Operation of the Wheel Speed Sensor
    94
  - Rear Wheel Speed Sensors
    94
- Removal
  94
- Hcu (Hydraulic Control Unit)
  95
  - Description
    95
  - Hydraulic Control Unit (Abs)
    95
  - Installation
    95
  - Installation
    96
- Tone Wheel Removal
  95
  - Cooling
    97
  - Diagnosis and Testing - Preliminary Checks
    97
  - Engine Cooling System Overheating
    97
  - Operation—Cooling System
    97
  - Cooling System Diagnosis—Diesel Engine
    98
  - Accessory Drive
    101
  - Belt Tensioners
    101
  - Drive Belts
    101
  - Visual Diagnosis
    101
  - Accessory Drive Belt Diagnosis Chart
    102
  - Noise Diagnosis
    102
  - Accessory Drive Belt Routing
    104
  - Drive Belt Tensioner
    104
  - Coolant
    105
  - Diagnosis and Testing - Cooling System Leaks
    106
- Engine
  105
Coolant

106
- Pressure Tester Method
  106
- Pressure Testing
  106
- Ultraviolet Light Method
  106
- Combustion Leakage Test - Without Pressure Tester
  107
- Internal Leakage Inspection
  107
- Standard Procedure - Adding Additional Coolant
  107
- Draining Coolant System
  108
- Standard Procedure - Draining Cooling System
  108
- Standard Procedure - Refilling Cooling System
  108
- Coolant Level Sensor Removal
  109
- Installation
  109
- Radiator Fan Removal
  109
- Description
  110
- Engine Block Heater Removal
  110
- Engine Coolant Temp Sensor
  110
- Installation
  110
  - Engine Coolant Temperature Sensor
    111
  - Installation
    111
  - Removal
    111
- Engine Coolant Thermostat
  111
  - Fan Drive Viscous Clutch Removal
    112
  - Installation
    112
  - Radiator Removal
    112
  - Removal
    112
  - Thermostat Housing Assembly
    112
  - Installation
    113
  - Radiator Assembly
    113
  - Description
    114
  - Operation
    114
  - Radiator and Fan Shroud
    114
  - Radiator Pressure Cap
    114
  - Radiator Pressure Cap - Typical
    114
  - Diagnosis and Testing - Radiator Pressure Cap
    115
  - Removal
    115
  - Water Pump
    115
  - Installation
    116
    
    Antenna Body & Cable
    117
    
    Audio/Video
    117
    
    Instrument Panel Antenna Cable
    117
    
    Instrument Panel Speaker
    118
    
    Radio
    118
    
    Speaker
    118
    
    Chime/Buzzer
    119
    
    Diagnosis and Testing - Chime Warning System
    120
    
    Central Timer Module
    121
    
    Electronic Control Modules
    121
  - Diagnosis and Testing - Central Timer Module
    122
    
    Hard Wired Inputs
    122
    
    Hard Wired Outputs
    122
    
    Messaging
    122
  - Operation
    122
  - Removal
    122
  - Central Timer Module
    123
  - Controller Antilock Brake
    123
  - Description
    123
  - Engine Control Module
    123
  - Installation
    123
  - Removal
    123
  - Ecm
    124
  - Installation
    124
  - Removal
    124
  - Description
    125
  - Operation
    125
  - Transmission Control Module
    125
    
    ATF Temperature Sensor
    126
    
    Brake Transmission Shift Interlock (Btsi)
    126
    
    Selector Lever Position
    126
    
    Tcm Signals
    126
    
    Adaptation
    127
    
    Downshift Safety
    127
    
    Driving Style Adaptation
    127
    
    Fill Pressure Adaptation
    127
    
    Controller Modes of Operation
    128
  - Standard Procedure - Tcm Adaptation
    128
  - Permanent Limp-In Mode
    128
  - Under Voltage Limp-In Mode
    128
  - Battery System
    129
  - Engine Systems
    129
Battery System

130
- Battery Holddown
  130
- Battery Tray
  130
- Charging System
  130
  - Diagnosis and Testing - Battery System
    130
  - Micro 420 Battery Tester
    130
- Operation
  130
  - Battery System Diagnosis
    131
  - System
    132
    
    Abnormal Battery Discharging
    133
    
    Battery Cleaning - Typical
    133
    
    Clean Battery Cable Terminal Clamp - Typical
    133
  - Battery Description
    134
  - Battery System Special Tools
    134
  - Special Tools
    134
  - Diagnosis and Testing - Battery
    135
  - Operation
    135
    
    Standard Procedure - Battery Charging
    136
    
    Battery Charging Time Table
    137
    
    Charging a Completely Discharged Battery
    137
    
    Charging Time Required
    137
    
    Voltmeter
    137
    
    Open Circuit Voltage Table
    138
  - Standard Procedure - Ignition-Off Draw Test
    138
  - Standard Procedure - Open-Circuit Voltage Test
    138
    
    Testing Open-Circuit Voltage
    138
    
    Battery Testing
    139
    
    Standard Procedure - Using Micro Battery Tester
    139
    
    Battery Cell Caps
    140
  - Battery System
    140
  - Hook Inside Battery Cap Holes
    140
  - Standard Procedure - Checking Battery Electrolyte Level
    140
  - Under Hood Battery Removal
    140
  - Auxiliary Battery Installation
    141
  - Auxiliary Battery Removal
    141
  - Under Hood Battery Installation
    141
  - Battery Cables
    142
  - Battery Holddown Description
    142
  - Description
    142
  - Diagnosis and Testing - Battery Cables
    142
  - Installation
    142
  - Operation
    142
  - Removal
    142
    
    Voltage Drop Test
    142
    
    Test Battery Negative Connection Resistance
    143
  - Battery Tray Description
    144
  - Installation
    144
  - Operation
    144
  - Removal
    144
Charging System

145
- Charging System
  146
- Generator Description
  146
- Generator Mounting
  146
- Installation
  146
- Operation
  146
- Removal
  146
- Description
  147
- Diagnosis and Testing - Generator Decoupler
  147
- Generator Decoupler Pulley
  147
- Operation
  147
  - End of Generator Shaft (Hex)
    148
  - Generator Decoupler Pulley (Ina)
    148
  - Generator Decoupler Pulley (Litens)
    148
  - INA Decoupler
    148
  - Removal
    148
    
    Decoupler Removal (Ina-Hex)
    149
    
    Decoupler Removal (Ina-Splined)
    149
    
    End of Generator Shaft (Splined)
    149
  - Installation
    149
    
    Litens Decoupler
    149
    
    Decoupler Installation (Ina Splined)
    150
    
    Decoupler Installation (Ina-Hex)
    150
    
    Decoupler Removal (Litens)
    150
    
    Decoupler Installation
    151
  - Voltage Regulator Description
    151
    
    Starting System
    152
    
    Diagnosis and Testing - Starting System
    153
    
    Cold Cranking Test
    154
    
    Volts-Amps Tester Connections
    154
    
    Feed Circuit Test
    155
    
    Control Circuit Testing
    156
    
    Test Ground Circuit Resistance
    156
    
    Test Positive Battery Cable
    156
    
    Test Starter Ground - Typical
    156
    
    Diagnosis and Testing - Starter Motor
    157
    
    Starter and Solenoid Location
    158
    
    Starter Removal/Installation
    158
    
    Starter Solenoid
    158
    
    Fuse / Relay Block
    159
    
    Starter Motor Relay
    159
    
    Wiring Trough - for Starter Removal
    159
    
    Fuse / Relay Block Cover
    160
    
    Heated Seats
    161
    
    Heated Systems
    161
  - Diagnosis and Testing - Driver Heated Seat Switch
    162
  - Diagnosis and Testing - Heated Seats
    162
  - Driver Heated Seat Switch Description
    162
  - Operation
    162
  - Diagnosis and Testing - Heated Seat Element
    163
  - Heated Seat Element Description
    163
  - Installation
    163
  - Operation
    163
  - Removal
    163
  - Diagnosis and Testing - Heated Seat Relay
    164
  - Diagnosis and Testing - Heated Seat Sensor
    164
  - Heated Seat Relay Description
    164
  - Heated Seat Sensor Description
    164
  - Installation
    164
  - Operation
    164
  - Removal
    164
  - Description
    165
  - Diagnosis and Testing - Passenger Heated Seat Switch
    165
  - Installation
    165
  - Operation
    165
  - Passenger Heated Seat Switch
    165
  - Removal
    165
    
    Horn
    167
    
    Glow Plug
    169
    
    Glow Plug Pliers
    169
    
    Ignition Control
    169
    
    Diagnosis and Testing - Glow Plug Relays
    170
    
    Glow Plug Relay
    170
    
    Instrument Cluster
    171
    
    Instrument Cluster Components
    172
  - Instrument Cluster Description
    172
    
    Gauges & Indicators
    174
    
    Gauges
    175
    
    Cluster Illumination
    176
  - Diagnosis and Testing - Instrument Cluster
    177
  - Indicators
    176
  - Input and Output Circuits
    176
Instrument Cluster

177
- Grounds
  177
- Cluster Connectors
  178
- Instrument Cluster Remove/Install
  178
- Rke/Immobilizer Module
  178
- Abs Indicator
  179
- Description
  179
- Installation
  179
- Operation
  179
- Airbag Indicator
  180
- Description
  180
- Operation
  180
- Ambient Temperature Indicator
  181
- Brake/Park Brake Indicator Description
  181
- Operation
  181
- Brake Wear Indicator
  182
- Description
  182
- Operation
  182
- Charging Indicator
  183
  - Clock
    183
  - Description
    183
  - Operation
    183
  - Coolant Low Indicator
    184
  - Description
    184
  - Operation
    184
  - Description
    185
  - Engine Temperature Gauge
    185
  - Fuel Filter Clogged Indicator
    185
  - Operation
    185
Clock

184
- Fuel System
  185
- Description
  186
- Fuel Gauge
  186
- Operation
  186
- Description
  187
- Gear Selector Indicator
  187
- High Beam Indicator
  187
- Operation
  187
- Description
  188
- Low Fuel Indicator
  188
- Low Oil Level Indicator
  188
- Operation
  188
- Description
  189
- Maintenance Indicator
  189
- Operation
  189
- Description
  190
- Malfunction Indicator Lamp (Mil)
  190
- Multi-Function Indicator
  190
- Operation
  190
Odometer

191
Speedometer

192
- Operation
  193
- Speedometer
  193
- Description
  194
- Operation
  194
- Traction Control Indicator
  194
  - Description
    195
  - Operation
    195
  - Traction Control Malfunction Indicator
    195
  - Turn Signal Indicator
    195
  - Description
    196
  - Operation
    196
  - Steering
    196
  - Wait-To-Start Indicator
    196
  - Operation
    197
  - Washer Fluid Indicator
    197
  - Water-In-Fuel Indicator Description
    197
  - Operation
    198
  - Lamps
    199
  - Lamps/Lighting - Exterior
    199
Lamps/Lighting - Exterior

201
- Backup Lamps
  201
- Brake Lamps
  201
- Daytime Running Lamps
  201
- Operation
  201
  - Transmission
    201
  - Front Fog Lamps
    202
  - Hazard Warning Lamps
    202
  - Headlamps
    202
  - Park Lamps
    202
  - Backup Lamp Bulb
    203
  - Bulb Specifications
    203
  - Removal
    203
  - Specifications - Lamps/Lighting - Exterior
    203
    
    Tail Lamp Socket Plate Remove/Install
    203
    
    Body
    204
  - Brake Lamp Switch
    204
    
    Brake Lamp Switch Location
    204
    
    Brake Lamp Switch Remove/Install
    204
  - Installation
    204
  - Removal
    204
  - Brake/Park Lamp Bulb
    205
  - Center High Mounted Stop Lamp Bulb
    205
  - CHMSL Bulb Remove/Install
    205
  - Installation
    205
  - Removal
    205
  - Tail Lamp Bulb Remove/Install
    205
  - Center High Mounted Stop Lamp un
    206
  - Clearance Lamp Bulb
    206
  - Clearance Lamp Unit
    206
  - Clearance Lamp Unit Remove/Install
    206
  - Installation
    206
  - Removal
    206
  - Daytime Running Lamp Relay
    207
  - Installation
    207
  - Removal
    207
    
    Seat Riser Cover
    207
    
    Fog Lamp Bulb Remove/Install
    208
  - Fog Lamp Relay
    208
  - Front Lamp Unit Bulbs Remove/Install
    208
  - Installation
    208
  - Removal
    208
  - Fog Lamp Switch
    209
  - Installation
    209
  - Removal
    209
  - Adjustment - Front Lamp Unit
    210
  - Fog Lamp Switch Remove/Install
    210
  - Front Lamp Unit
    210
  - Installation
    210
  - Lamps/Lighting - Interior
    210
  - Removal
    210
    
    Vehicle Preparation for Front Lamp Unit Alignment
    210
    
    Fog Lamp Cut-Off Pattern
    211
    
    Front Lamp Unit Adjusting Screws
    211
    
    Front Lamp Unit Alignment
    211
    
    Low Beam Headlamp Cut-Off Pattern
    211
  - Front Position Lamp Bulb Removal
    212
  - Front Turn/Park/Side Marker Lamp
    212
  - Installation
    212
  - Position Lamp Bulb Remove/Install
    212
  - Removal
    212
  - Headlamp Leveling Motor
    213
  - Installation
    213
  - Removal
    213
    
    Headlamp Leveling Motor Remove/Install
    214
    
    Headlamp Leveling Switch Remove/Install
    214
  - Installation
    214
  - High Beam Headlamp Bulb Removal
    215
  - High Beam Headlamp Bulb Remove/Install
    215
  - Installation
    215
  - License Plate Lamp Bulb
    215
  - Installation
    216
  - License Plate Lamp Unit Remove/Install
    216
  - Low Beam Headlamp Bulb
    216
  - Removal
    216
  - Installation
    217
  - Multi-Function Switch Removal
    217
  - Installation
    218
  - Park Brake Switch
    218
  - Park Brake Switch Remove/Install
    218
  - Removal
    218
  - Rear Side Marker Lamp Bulb
    219
  - Rear Turn Lamp Bulb
    219
  - Repeater Lamp Bulb
    220
  - Repeater Lamp Unit
    220
  - Tail Lamp Unit
    221
  - Tail Lamp Unit Remove/Install
    221
  - Turn Signal Relay
    222
  - Lamps/Lighting - Interior
    223
Lamps/Lighting - Interior

224
- Class
  224
- Exterior Lighting Circuit
  224
- Interior Lighting Circuit
  224
- Operation
  224
- Specifications - Interior Lighting
  224
- Van Models
  224
- Ash Receiver/Cigar Lighter Lamp Unit
  225
- Cargo/Dome Lamp Bulb
  225
- Installation
  225
- Removal
  225
- Cargo Lamp Switch
  226
- Cargo/Dome Lamp Unit
  226
- Installation
  226
- Removal
  226
- Removal - Bulkhead
  226
- Removal - Instrument Panel
  226
- Removal - Rear Pillar
  226
- Dome/Reading Lamp Bulb
  227
- Installation - Bulkhead
  227
- Installation - Instrument Panel
  227
- Installation - Rear Pillar
  227
- Removal
  227
- Dome Lamp/Intrusion Sensor Bulb
  228
- Dome/Reading Lamp Unit Removal
  228
- Installation
  228
- Dome Lamp/Intrusion Sensor
  229
- Door Jamb Switch
  229
- Entry/Exit Lamp Bulb
  229
- Installation
  229
- Removal
  229
- Entry/Exit Lamp Bulb Remove/Install
  230
- Entry/Exit Lamp Unit
  230
  - Entry/Exit Lamp Unit Remove/Install
    230
  - Installation
    230
  - Removal
    230
  - Installation
    231
- Time Delay Relay
  230
  - Central Locking
    233
  - Door Lock Motor
    233
  - Power Locks
    233
  - Power Systems
    233
  - Master Lock Switch
    234
  - Power Lock Switch
    234
  - Remote Keyless Entry Transmitter
    234
  - Diagnosis and Testing - Power Mirror Switch
    235
  - Mirror Switch Test
    235
  - Power Mirror Switch
    235
  - Power Mirrors
    235
  - Power Window Switch
    237
  - Power Windows
    237
  - Window Motor
    237
  - Window Switch
    237
  - Restraints
    239
  - Restraints Description
    240
    
    Supplemental Restraint System
    240
    
    Active Restraints
    241
    
    Passive Restraints
    241
    
    SRS Logo
    241
  - Operation
    242
  - Diagnosis and Testing - Supplemental Restraint System
    243
  - Warnings - Restraint System
    243
Restraints

242
- Standard Procedure - Handling Non-Deployed Supplemental Restraints
  244
- Standard Procedure - Service after a Supplemental Restraint Deployment
  244
- Supplemental Restraint Storage
  244
- Standard Procedure - Verification Test
  245
  - Vacuum Heater and A/C Outlets - Typical
    245
  - Wear Safety Glasses and Rubber Gloves
    245
  - ACM Bracket
    246
  - Airbag Control Module
    246
  - Description
    246
  - Way Data Link Connector
    246
  - Operation
    247
  - Airbag Control Module Location
    248
  - Removal
    248
    
    ACM Cover
    249
    
    Airbag Control Module Remove/Install
    249
  - Installation
    249
- Control Module Bracket
  249
Clockspring

250
- ACM Cover Base Plate
  250
- Description
  250
  - Operation
    251
    
    Standard Procedure - Clockspring Centering
    251
    
    Clockspring Centering
    252
    
    Clockspring Remove/Install
    253
    
    Clockspring Pigtail Routing
    254
    
    Driver Airbag
    254
    
    Driver Airbag Housing
    254
    
    Driver Airbag Trim Cover
    254
    
    Driver Airbag Operation
    255
    
    Driver Airbag Remove/Install
    256
  - Installation
    256
  - Removal
    256
  - Front Seat Belt & Retractor Removal
    257
  - Operation
    257
    
    Front Seat Belt Lower Anchor
    258
    
    Front Seat Belt Turning Loop
    258
    
    Turning Loop Height Adjuster
    258
    
    Front Seat Belt Retractor
    259
  - Installation
    259
  - Front Seat Belt Buckle
    260
  - Front Seat Belt Buckle Remove/Install
    260
  - Removal
    260
  - Description
    261
  - Installation
    261
  - Passenger Airbag
    261
    
    Passenger Airbag Door
    261
    
    Passenger Airbag Unit
    261
  - Operation
    262
  - Removal
    262
  - Passenger Airbag Remove/Install
    263
  - Installation
    264
  - Installation
    265
  - Passenger Airbag Bracket
    265
  - Passenger Airbag Bracket Remove/Install
    265
  - Rear Seat Belt & Retractor Removal
    265
    
    Left Outboard Rear Seat Belt Lower Anchor
    266
    
    Rear Seat Belt Turning Loop
    266
    
    Right Outboard or Center Rear Seat Belt Lower Anchor
    266
    
    Turning Loop Trim Cover
    266
  - Installation
    267
  - Rear Seat Belt Buckle
    267
  - Rear Seat Belt Retractor
    267
  - Removal - Inboard
    267
  - Inboard Rear Seat Belt Buckle
    268
  - Installation - Inboard
    268
  - Outboard Rear Seat Belt Buckle
    268
  - Removal - Outboard
    268
  - Description
    269
  - Installation - Outboard
    269
  - Operation
    269
  - Seat Belt Switch
    269
  - Seat Belt Tensioner
    269
  - Seat Belt Tensioner Operation
    270
  - Removal
    271
  - Seat Belt Turning Loop Adjuster
    271
  - Installation
    272
    
    Seat Belt Turning Loop Adjuster Remove/Install
    272
    
    Speed Control
    273
    
    Speed Control Switch Functions
    274
    
    Cable
    275
    
    Servo
    275
    
    Speed Control Switch Location
    275
    
    Switch
    275
    
    Diagnosis and Testing - Vehicle Theft Security
    277
  - Description
    278
  - Installation
    278
  - Intrusion Sensor Removal
    278
  - Security System Module Removal
    278
  - Sentry Key Remote Entry Module Description
    278
- Vehicle Theft Security
  277
Vehicle Theft Security

278
- Operation
  279
- Remote Keyless Entry (Rke)
  279
- Removal
  279
  - Sentry Key Immobilizer
    279
  - Sentry Key Remote Entry Module
    279
  - Installation
    280
  - Sentry Key Remote Entry Module Transponder Ring
    280
  - Siren Removal
    280
  - Operation
    281
  - Transponder Key Description
    281
  - Wipers/Washers
    283
  - Wiper & Washer System
    284
Wipers/Washers

285
- Operating Modes
  285
- Windshield Wiper/Washer Switch
  286
- Cleaning - Wiper & Washer System
  287
  - Diagnosis and Testing - Wiper & Washer System
    287
  - Washer System
    287
  - Wiper System
    287
  - Inspection - Wiper & Washer System
    288
  - Wiper Blade Inspection
    288
  - Check Valve Description
    289
  - Description
    289
  - Installation
    289
  - Operation
    289
  - Removal
    289
  - Washer Fluid Level Switch
    289
  - Operation
    290
  - Washer Hoses/Tubes Description
    290
  - Washer Plumbing
    290
  - Description
    291
  - Installation
    291
  - Operation
    291
  - Removal
    291
  - Washer Nozzle
    291
  - Washer Nozzle Remove/Install
    291
  - Washer Pump/Motor
    291
  - Installation
    292
  - Operation
    292
  - Removal
    292
  - Washer Pump/Motor Remove/Install
    292
  - Description
    293
  - Heat Shield & Air Cleaner Housing
    293
  - Operation
    293
  - Removal
    293
  - Washer Reservoir
    293
  - Installation
    294
    
    Washer Reservoir Mounting
    294
    
    Washer Reservoir Remove/Install
    294
  - Wiper Arm Description
    295
  - Installation
    296
  - Operation
    296
  - Removal
    296
    
    Wiper Arm Puller - Typical
    296
    
    Wiper Arm Remove/Install
    296
  - Description
    297
  - Operation
    297
  - Wiper Blade
    297
  - Installation
    298
  - Removal
    298
  - Wiper Blade Remove/Install
    298
  - Operation
    299
  - Removal
    299
  - Wiper Linkage Description
    299
    
    Wiper Linkage Module
    299
    
    Ventilation Housing
    300
    
    Wiper Linkage Module Remove/Install
    300
  - Description
    301
  - Installation
    301
  - Operation
    301
  - Removal
    301
  - Wiper Motor
    301
  - Wiper Motor Remove/Install
    302
  - Wiper Relay Description
    302
  - Operation
    303
  - Installation
    304
  - Removal
    304
    
    Wiring
    305
    
    8W-01 Wiring Diagram Information
    307
    
    Description - How to Use Wiring Diagrams
    307
    
    Symbols
    307
    
    Wiring Diagram Information
    307
  - Description - Circuit Information
    311
  - Description - Connector, Ground and Splice Information
    311
  - Description - Section Identification and Information
    311
  - Wiring Section Chart
    311
  - Diagnosis and Testing - Wiring Harness
    312
  - Warnings - General
    312
    
    Intermittent and Poor Connections
    313
    
    Standard Procedure - Electrostatic Discharge (Esd) Sensitive Devices
    313
  - Standard Procedure - Testing of Voltage Potential
    313
  - Removal
    314
  - Standard Procedure - Testing for Ashort to Ground on Fuses Powering Several Loads
    314
  - Standard Procedure - Testing for Avoltage Drop
    314
- Troubleshooting Wiring Problems
  313
Diode

315
- Diode Identification
  315
- Installation
  315
  - Removal of Dress Cover
    315
  - Testing for Voltage Drop
    315
Wire

316
- Standard Procedure - Wire Splicing
  316
Terminal

316
- Heat Shrink Tube
  316
- Installation
  316
  - Solder Splice
    316
  - Splice Band
    316
  - 8W-02 Component Index
    317
  - 8W-10 Power Distribution
    319
  - 8W-11 Fuse Block
    353
  - Fuse/Relay Block
    354
  - Relay Block
    355
  - 8W-15 Ground Distribution
    393
  - 8W-18 Bus Communications
    421
  - 8W-20 Charging System
    427
  - 8W-21 Starting System
    433
  - 8W-30 Fuel/Ignition System
    435
  - 8W-31 Transmission Control System
    453
  - 8W-33 Vehicle Speed Control
    463
  - 8W-35 Antilock Brakes
    467
  - 8W-39 Vehicle Theft Security System
    475
  - 8W-40 Instrument Cluster
    489
  - 8W-41 Horn/Cigar Lighter
    497
  - 8W-42 Air Conditioner/Heater
    501
  - 8W-43 Airbag System
    525
  - 8W-44 Interior Lighting
    529
  - 8W-45 Central Timer Module
    541
  - 8W-47 Audio System
    549
  - 8W-48 Rear Window Defogger
    555
  - 8W-50 Front Lighting
    561
  - 8W-51 Rear Lighting
    577
  - 8W-52 Turn Signals
    587
  - 8W-53 Wipers
    593
  - 8W-54 Trailer Tow
    597
  - 8W-55 Navigation/Telecommunications
    601
  - 8W-60 Power Windows
    605
  - 8W-61 Power Door Locks
    609
  - 8W-62 Power Mirrors
    617
  - 8W-63 Power Seats
    621
  - 8W-70 Splice Information
    625
  - 8W-80 Connector Pin-Outs
    627
  - A/C Control Module-Roof - Black
    630
  - A/C Fan Switch
    630
  - A/C Switch-Roof
    630
  - Accelerator Pedal Position Sensor - Black
    631
  - Air Outlet Temperature Sensor
    631
  - Airbag Control Module - Yellow
    631
  - Airbag Squib-Driver
    631
  - Airbag Squib-Passenger - Yellow
    632
  - Ambient Temperature Sensor
    632
  - Ash Receiver Lamp
    632
  - Automatic Temperature Control Module C1 - Brown
    632
  - Automatic Temperature Control Module C2
    633
  - Auxiliary Heater Relay (in Relay Block)
    635
  - Auxiliary Heater Switch
    635
  - Battery Relay-Auxiliary - Black
    635
  - Blower Motor Resistor Block
    635
  - Blower Motor Resistor Block C2
    636
  - Blower Motor Resistor Block C3
    636
  - Blower Motor-Front - Black
    636
  - Body Plug Connector
    636
  - Boost Pressure Solenoid - Black
    637
  - Brake Fluid Level Switch
    637
  - Brake Lamp Switch C2 - Black
    637
  - Brake Wear Sensor-Left Front
    637
  - Brake Wear Sensor-Left Rear
    638
  - Brake Wear Sensor-Right Front
    638
  - Brake Wear Sensor-Right Rear
    638
  - C100 - (Main Body Side)
    638
  - C101 - Yellow (Engine Side)
    639
  - C101 - Yellow (Main Body Side)
    639
  - C200 - Black (Dash Side)
    639
  - C200 - Black (Main Body Side)
    640
  - C201 - (Dash Side)
    640
  - C201 - Black (Main Body Side)
    641
  - C202 - (Dash Side)
    641
  - C202 - Black (Main Body Side)
    641
  - C203 - (Dash Side)
    642
  - C203 - Black (Main Body Side)
    642
  - C204 - Gray (Dash Side)
    642
  - C204 - Gray (Main Body Side)
    642
  - C205 - Yellow (Dash Side)
    643
  - C205 - Yellow (Main Body Side)
    643
  - C206 - (Dash Side)
    643
  - C206 - (Main Body Side)
    643
  - C207 - (Dash Side)
    644
  - C207 - (Main Body Side)
    644
  - C208 - (Cabin Side)
    644
  - C208 - (Dash Side)
    644
  - C209 - (Dash Side)
    645
  - C210 - (Driver Door Side)
    645
  - C210 - Black (Main Body Side)
    645
  - C211 - (Power Mirror Switch Side)
    645
  - C214 - Lt. Blue (Cabin Side)
    646
  - C214 - Lt.blue (Dash Side)
    646
  - C215 - Black (Cabin Side)
    646
  - C215 - Black (Main Body)
    646
  - C217 - (Cabin Side)
    647
  - C217 - (Main Body Side)
    647
  - C218 - (Cabin Side)
    647
  - C218 - (Main Body Side)
    647
  - C219 - (Main Body Side)
    648
  - C219 - Black (Cabin Side)
    648
  - C220 - (Cigarette Side)
    648
  - C220 - (Dash Side)
    648
  - C221 - (Main Body Side)
    649
  - C221 - (Passenger Door Side)
    649
  - C224 - (Atc Motor/Solenoid Side)
    649
  - C224 - (Main Body Side)
    649
  - C225 - (Dash Side)
    650
  - Cabin Heater Assembly C1
    650
  - Cabin Heater Assembly C2
    650
  - Camshaft Position Sensor - Black
    650
  - Central Timer Module C1 - Pink
    651
  - Central Timer Module C2 - Lt.green
    651
  - Cigar Lighter
    651
  - Cigar Lighter Lamp
    652
  - Circulation Pump (Cabin Heater Module)
    652
  - Circulation Pump (Rest System)
    652
  - Circulation Pump Diode
    652
  - Clockspring C2
    653
  - Courtesy Lamp-Driver Door
    653
  - Courtesy Lamp-Left Sliding Door
    653
  - Courtesy Lamp-Passenger Door
    654
  - Courtesy Lamp-Right Sliding Door
    654
  - Crankcase Heater - Black
    654
  - Crankshaft Position Sensor - Black
    654
  - Cylinder Lock Switch-Driver
    655
  - Data Link Connector - Black
    655
  - Differential Lock Solenoid Valve
    655
  - Dome Lamp
    655
  - Door Lock Motor/Ajar Switch Assembly-Driver C1
    656
  - Door Lock Motor/Ajar Switch Assembly-Driver C2
    656
  - Door Lock Motor/Ajar Switch Assembly-Left Sliding C1
    656
  - Door Lock Motor/Ajar Switch Assembly-Left Sliding C2
    656
  - Door Lock Motor/Ajar Switch Assembly-Passenger C2
    657
  - Door Lock Motor/Ajar Switch Assembly-Rear C1
    657
  - Door Lock Motor/Ajar Switch Assembly-Rear C2
    657
  - Door Lock Motor/Ajar Switch Assembly-Right Sliding C1
    657
  - Dosing Pump
    658
  - Egr Valve - Black
    658
  - Engine Control Module C1 - Black
    658
  - Engine Control Module C2 - Black
    658
  - Engine Control Module C3 - Black
    659
  - Engine Control Module C4 - Black
    659
  - Engine Control Module C5 - Gray
    660
  - Engine Coolant Level Switch - Black
    660
  - Engine Coolant Temperature Sensor - Black
    660
  - Engine Oil Sensor - Black
    660
  - Evaporator Temperature Sensor
    661
  - Fuel Injector No. 1 - Black
    661
  - Fuel Injector No. 2 - Black
    661
  - Fuel Injector No. 3 - Black
    661
  - Fuel Injector No. 4 - Black
    662
  - Fuel Injector No. 5 - Black
    662
  - Fuel Level Sensor
    662
  - Fuel Pressure Sensor - Black
    662
  - Fuel Shutdown Solenoid
    663
  - Fuel Temperature Sensor
    663
  - Fuse Block No. 1 C1
    663
  - Fuse Block No. 1 C2
    663
  - Fuse Block No. 1 C3 - Black
    664
  - Fuse Block No. 1 C4 - Black
    664
  - Fuse Block No. 1 C5 - Black
    664
  - Glow Plug Control Module C1 - Black
    664
  - Glow Plug Control Module C2 - Black
    665
  - Headlamp Adjust Switch - Black
    665
  - Headlamp Assembly-Left - Black
    665
  - Headlamp Assembly-Right - Black
    666
  - Heat Exchanger Connector
    666
  - Heat Exchanger Switch
    666
  - Heated Seat Module-Driver
    666
  - Heated Seat Module-Passenger
    667
  - Heated Seat Switch-Driver
    667
  - Heated Seat Switch-Passenger
    667
  - Heater Timer-Auxiliary
    667
  - Hood Ajar Switch - Black
    668
  - Horn (Vtss)
    668
  - Horn-Switch
    668
  - Ignition Lock Switch - Black
    669
  - Instrument Cluster C1
    669
  - Instrument Cluster C2 - White
    669
  - Instrument Panel Socket - Black
    670
  - Intake Air Temperature Sensor - Black
    670
  - Interior Lamp No. 1
    670
  - Interior Lamp No. 2
    670
  - Interior Lamp No. 4
    671
  - Interior Lamp No. 5
    671
  - Interior Lamp-Left - Black
    671
  - Interior Lamp-Middle Front
    671
  - Interior Lamp-Middle Rear
    672
  - Interior Lamp-Rear No. 1 - Black
    672
  - Interior Lamp-Rear No. 2 - Black
    672
  - Interior Lamp-Right - Black
    673
  - Interior Light Switch
    673
  - Interior Light Switch-Driver
    673
  - Interior Light Switch-Passenger
    673
  - Interior Light Switch-Rear
    674
  - Interior Lighting Connector
    674
  - Intrusion Sensor No. 1 - Black
    674
  - Intrusion Sensor No. 2 - Black
    674
  - Kick down Switch - Black
    675
  - License Plate Lamp No. 1
    675
  - License Plate Lamp No. 2
    675
  - Locker Switch No. 1
    675
  - Low Fuel Pressure Sensor - Black
    676
  - Map/Reading Lamp Switch
    676
  - Marker Lamp No. 1-Left Front
    676
  - Marker Lamp No. 1-Right Front
    676
  - Marker Lamp No. 2-Left Front
    677
  - Marker Lamp No. 2-Right Front
    677
  - Marker Lamp-Left Center
    677
  - Marker Lamp-Left Rear
    677
  - Marker Lamp-Right Rear
    678
  - Mass Air Flow Sensor - Black
    678
  - Master Door Lock Switch
    678
  - Metering Pump
    678
  - Panic Alarm Switch - Black
    679
  - Parking Brake Switch
    679
  - Power Mirror Motor-Driver
    679
  - Power Mirror Motor-Passenger - Black
    679
  - Power Window Motor-Driver
    680
  - Power Window Motor-Passenger
    680
  - Power Window Switch-Driver
    680
  - Power Window Switch-Master
    680
  - Radio Antenna
    681
  - Radio C1 - Black
    681
  - Radio C2
    681
  - Radio/Cellular Antenna
    681
  - Reading Lamp Connector
    682
  - Recirculated Air Solenoid Valve
    682
  - Refrigerant Pressure Sensor
    682
  - Remote Keyless Entry Antenna
    682
  - Seat Belt Tensioner-Driver - Yellow
    683
  - Seat Belt Tensioner-Passenger - Yellow
    683
  - Security System Module C1 - Brown
    683
  - Security System Module C2 - Lt.green
    684
  - Sentry Key Remote Entry Module (Skreem)
    684
  - Shifter Assembly - Black
    684
  - Siren - Black
    685
  - Speaker-Left Front Door Assembly C1
    685
  - Speaker-Left Front Door Assembly C2
    685
  - Speaker-Right Front Door
    685
  - Speaker-Right Rear
    686
  - Speed Control Switch
    686
  - Tail Lamp Assembly-Left - Black
    686
  - Tail Lamp Assembly-Right - Black
    686
  - Temperature Switch
    687
  - Towing/Intrusion Sensor On/Off Switch
    687
  - Trailer Tow Connector - Black
    687
  - Trailer Tow Control Module C1 - Black
    688
  - Trailer Tow Control Module C2 - Black
    688
  - Transmission Control Module C1 - Black
    688
  - Transmission Control Module C2 - Black
    688
  - Transmission Solenoid Assembly - Black
    689
  - Turn Signal No. 1-Left Front - Black
    689
  - Turn Signal No. 1-Right Front - Black
    689
  - Turn Signal No. 2-Left Front
    689
  - Turn Signal No. 2-Right Front
    690
  - Warm Air Auxiliary Heater Assembly C1
    690
  - Warm Air Auxiliary Heater Assembly C2
    690
  - Washer Pump Motor-Front
    690
  - Water in Fuel Sensor - Black
    691
  - Wheel Speed Sensor-Left Front
    691
  - Wheel Speed Sensor-Left Rear
    691
  - Wheel Speed Sensor-Right Front
    691
  - Window Defogger Module-Rear - Brown
    692
  - Window Defogger Switch-Rear - Black
    692
  - Window Defogger-Left Rear
    692
  - Window Defogger-Right Rear
    692
  - Wiper/Turn Signal/Engine Start Control Module (Fuse Block No. 1)
    693
  - 8W-91 Connector/Ground/Splice Location
    695
  - Connector/Ground/Splice Location
    695
  - Connectors
    695
  - 8W-97 Power Distribution
    733
  - Fuse Block #1
    734
Power Distribution

734
- Circuit Breaker Description
  734
- Description
  734
- Diagnosis and Testing - Cigar Lighter Outlet
  734
- Diagnosis and Testing - Circuit Breaker
  734
- Operation
  734
- Removal
  734
- Description
  735
- Fuse Block #2
  735
- Installation
  735
- Operation
  735
- Power Distribution Center
  735
- Power Outlet
  735
- Removal
  735
Cigar Lighter Outlet

735
- Description
  736
- Diagnosis and Testing - Power Outlet
  736
- Installation
  736
- Operation
  736
- Relay
  736
- Removal
  736
Relay

737
- Diagnosis and Testing - Relay
  737
- Diagnosis and Testing - Relay Circuit Test
  737
- Installation
  737
- Operation
  737
- Removal
  737
  - Engine Description
    740
  - Compression Specifications
    741
  - Engine Description
    741
  - Standard Procedure - Compression Testing Engine
    741
  - Standard Procedure - Cylinder Leak down Test
    741
    
    Cylinder Leak down Values
    742
    
    Possible Cause for Pressure Loss
    742
  - Removal - Engine Cover
    742
  - Standard Procedure - Determining Cylinder Pressure Loss
    742
    
    2.7L Engine
    743
    
    Engine Cover
    743
    
    Transmission Connections
    744
    
    Engine Hoist Connection
    745
    
    Engine Lifting Fixture
    745
    
    Front Cross Plate
    745
  - Installation - Engine Cover
    745
  - Specifications - Torque Specifications
    746
  - Air Cleaner Element
    758
  - Air Cleaner Housing Removal
    758
  - Installation
    758
  - Removal
    758
  - Cylinder Head
    759
  - Head Bolt Inspection
    759
  - Standard Procedure - Cylinder
    759
  - Standard Procedure - Measure Cylinder Head Surface
    759
    
    Camshaft Housing
    760
    
    Removal - Cylinder Head
    760
    
    Removal - Cylinder Head Front Cover
    761
    
    Cylinder Head Front Cover
    762
    
    Removal - Cylinder Head Guide Rail
    762
    
    Cylinder Head Bolt Torque Sequence
    763
  - Cover
    764
  - Installation - Cylinder Head Guide Rail
    764
  - Standard Procedure - Checking Camshaft Position
    765
- Installation - Cylinder Head
  763
Camshaft(S)

765
- Checking Camshaft Position
  765
- Camshaft Alignment
  766
- Removal
  766
  - Camshafts and Housing Assembly
    767
  - Installation
    767
  - Cylinder Head Cover
    768
  - Cylinder Head Cover(S)
    768
  - Installation
    768
  - Removal
    768
  - Removal - Valve Springs
    769
  - Removal - Valves
    769
  - Valve Compressor
    769
  - Valve Springs
    769
  - Installation - Valve Springs
    770
    
    Valve Assembly
    770
    
    Valve Stem Seal
    770
  - Installation - Valves
    771
    
    Valve Seal Installation
    771
    
    Core Hole Plug Removal
    772
  - Engine Block
    772
  - Standard Procedure - Measuring Cylinder Bores
    772
  - Standard Procedure - Replacing Engine Core and Oil Gallery Plugs
    772
Crankshaft

773
- Assign Crankshaft Bearing Shells
  773
- Crankshaft and Block Journals
  773
- Measuring Cylinder Bores
  773
- Removal
  773
  - Standard Procedure - Measure Crankshaft and Block Journals
    773
  - Crankshaft Assembly
    774
  - Installation
    774
  - Crankshaft Oil Seal - Rear
    775
  - Installation
    775
  - Rear Main Seal/Adapter
    775
  - Removal
    775
  - Crankshaft Oil Seal - Front
    776
    
    Front Seal Removal/Installation
    776
    
    Flywheel Assembly
    777
  - Flywheel Removal
    777
  - Installation
    777
  - Crankshaft Lock
    778
  - Description
    778
  - Piston & Connecting Rod
    778
  - Standard Procedure - Checking and Repairing Connecting Rods
    778
    
    Measuring Connecting Rods
    779
    
    Piston and Connecting Rod Assembly
    779
    
    Connecting Rod Specifications
    780
    
    Measuring Piston Protrusion
    780
  - Removal
    780
  - Standard Procedure - Measuring Piston Protrusion
    780
  - Installation
    781
    
    Piston and Connecting Rod Installation
    783
    
    Measuring Piston Ring Side Clearance
    784
  - Piston Rings
    784
  - Ring Gap Measurement Chart
    784
  - Standard Procedure - Piston Ring Fitting
    784
    
    Compression Ring Installation
    785
    
    Ring Gap Orientation
    785
  - Vibration Damper Removal
    785
  - Vibration Damper/Crankshaft Pulley
    785
  - Description
    786
  - Installation
    786
  - Operation
    786
  - Removal
    786
  - Vacuum Pump
    786
  - Installation
    787
  - Left Mount Removal
    787
  - Removal
    787
  - Right Mount
    787
  - Installation - Oil Separator
    788
  - Oil Cooler & Lines
    788
  - Removal - Oil Separator
    788
Oil

788
- Right Engine Mount
  788
- Engine Oil Cooler
  789
- Oil Jet
  789
  - Description
    789
  - Installation
    789
  - Oil Filter Removal
    789
  - Oil Jet Location
    789
  - Removal
    789
  - Installation
    790
  - Oil Pan Removal
    790
    
    Oil Pan Bolts
    791
    
    Oil Pan Gasket
    791
  - Oil Pump
    791
  - Removal- Oil Pump Chain
    791
  - Installation - Oil Pump Chain
    792
    
    Installing Oil Pump Chain Temporary Link
    792
    
    Oil Pump Chain Link Removal
    792
    
    Installing Assembly Inserts into Riveting Tool
    793
    
    Installing New Riveted Link
    793
    
    Removing Oil Pump Chain Temporary Link
    793
  - Description
    794
  - New Link Riveting
    794
  - Oil Temperature Sensor
    794
  - Operation
    794
  - Rivet Inspection
    794
  - Installation
    795
  - Intake Manifold
    795
  - Oil Level Sensor
    795
  - Removal
    795
  - Installation
    796
  - Exhaust Manifold
    797
  - Installation
    797
  - Removal
    797
  - Timing Chain Cover
    797
  - Installation
    798
  - Removal - Intermediate Gear
    799
  - Removal - Tensioning and Slide Rails
    799
  - Timing Belt/Chain and Sprockets
    799
    
    Tensioning and Slide Rails
    800
    
    High Ressure Pump Intermediate Gear
    801
  - Removal - Timing Chain Tensioning Rail
    801
    
    Securing Timing Chain to Sprocket
    802
    
    Separating Timing Chain with Special
    802
    
    Thrust Pin Position
    802
    
    Installing Temporary Link
    803
    
    Timing Chain Temporary Link
    803
  - Installation - Intermediate Gear
    804
  - Installation - Tensioning and Slide Rail
    804
  - Installation - Timing Chain Tensioning Rail
    804
  - Installation - Timing Chain
    805
    
    Insert New Riveted Link
    806
    
    Removing Temporary Link
    806
    
    Installing Link Outer Plate
    807
    
    Installing Riveting Inserts into Riveting Tool
    807
    
    Pressing in New Riveted Link
    807
    
    Riveting Links of the Riveted Link
    807
  - Timing Chain Tensioner Removal
    808
  - Installation
    809
  - Exhaust System
    811
  - Diagnosis and Testing - Diesel Engine
    812
Exhaust System

812
- Exhaust System Diagnosis Chart
  812
Tailpipe

813
- Description
  814
- Diagnosis and Testing - Charge Air Cooler System - Leaks
  814
- Operation
  814
  - Turbocharger Components
    814
  - Charge Air Cooler
    815
  - Cleaning
    815
  - Inspection
    815
  - Installation
    815
  - Removal
    815
  - Charge Pressure Vacuum Transducer
    816
  - Operation
    816
  - Turbocharger Description
    816
    
    Turbocharger Vacuum Routing
    816
    
    Removal - Vacuum Transducer
    817
  - Installation - Vacuum Transducer
    818
  - Frame & Bumpers
    819
  - Front Bumper - Steps Removal
    820
  - Front Fascia Removal
    820
  - Installation
    820
  - Installation
    821
  - Rear Bumper - Step Removal
    821
  - Rear Fascia Removal
    821
  - Specifications - Frame Dimensions
    822
Bumpers

820
Frame

822
- Vehicle Preparation
  822
- Engine Cradle Crossmember
  824
  - Engine Mount
    824
  - Power Steering Hose Bracket
    825
  - Steering Gear
    825
  - Engine Cradle Bolts
    826
  - Heat Shield
    826
  - Identification Plate
    826
  - Installation
    826
  - Rear Crossmember - Transmission Removal
    827
Trailer Hitch

827
Fuel Delivery

833
- Fuel Drain Tubes
  833
  - Description
    833
  - Diagnosis and Testing - Fuel Supply
    833
  - Fuel Filter
    833
    
    High-Pressure Lines
    833
    
    Low-Pressure Lines
    833
  - Operation
    833
  - Removal
    833
  - Restrictions
    833
  - Special Tools Fuel System
    833
  - Fuel Filter and Bracket
    834
  - Fuel Lines
    834
  - Installation
    834
  - Removal - High Pressure Lines
    834
  - Description - Low Pressure Pump
    835
  - Fuel Pump
    835
  - Installation - High Pressure Lines
    835
  - Low Pressure Side
    835
  - Operation
    835
    
    High Pressure Pump
    836
    
    High Pressure Side
    836
  - Operation - Low Pressure Pump
    836
  - Removal - High Pressure Pump
    836
  - Removal - Low Pressure Pump
    837
  - Installation - High Pressure Pump
    838
  - Vacuum Pump and Low Pressure Fuel Pump Assemblies
    838
  - Description
    839
  - Fuel Rail
    839
  - Installation - Low Pressure Pump
    839
  - Operation
    839
  - Removal
    839
  - Description
    840
  - Fuel Pressure Solenoid
    840
  - Fuel Tank
    840
  - Removal
    840
  - Fuel Tank Assembly
    841
  - Fuel Tank Module Description
    841
  - Installation
    841
  - Removal
    841
    
    Align Tank Module
    842
    
    Fuel Gauge Sending Unit
    842
    
    Fuel Tank Module R/I
    842
  - Installation
    842
  - Fuel Level Sending Unit / Sensor Description
    843
  - Installation
    843
  - Removal
    843
  - Description
    844
  - Hi Pressure Fuel Shutoff Sol
    844
  - Operation
    844
  - Water in Fuel Sensor Description
    844
    
    Accelerator Pedal Position Sensor
    845
    
    Boost Pressure Sensor
    845
  - Diagnosis and Testing - Boost Pressure Sensor
    846
  - Installation
    846
  - Operation
    846
  - Removal
    846
  - Camshaft Position Sensor
    847
- Fuel Injection
  845
Accelerator Pedal Position Sensor

846
- Cam Position Sensor
  847
- Description
  847
- Installation
  847
- Operation
  847
- Removal
  847
- Crankshaft Position Sensor
  848
- Description
  848
- Fuel Injector
  848
- Installation
  848
- Operation
  848
- Removal
  848
Fuel Injector

848
- Injector Closed (with High Pressure Applied)
  849
- Injector Opens (Start of Injection)
  849
- Injector Closes (End of Injection)
  850
- Injector Opens Fully
  850
- Standard Procedure - Cleaning Fuel Injectors
  850
- Standard Procedure - Injector
  850
- Installation
  851
- Removal
  851
  - Fuel Injector Removal / Installation
    852
  - Description
    853
  - Fuel Pressure Sensor
    853
    
    Fuel Rail Pressure Sensor
    854
    
    Fuel Pressure Solenoid - Typical
    855
    
    Fuel Pressure Solenoid Operation
    855
    
    Fuel Pressure Solenoid Assembly
    856
  - Description
    857
  - Inlet Air Temperature Sensor
    857
  - Operation
    857
  - Manifold Air Flow (Maf) Sensor
    858
Fuel Temperature Sensor

858
- Description
  858
- Inlet Air Temperature
  858
- Installation
  858
- Operation
  858
- Removal
  858
- Installation
  859
- Removal
  859
  - Steering
    861
  - Steering Components
    861
  - Diagnosis and Testing - Power Steering System
    862
  - Steering Noise
    862
  - Binding and Sticking
    863
  - Insufficient Asst. or Poor Return to Center
    863
  - Loose Steering and Vehicle Lead
    864
  - Column
    865
  - Intermediate Shaft
    865
  - Key/Lock Cylinder
    866
  - Steering Column Bolts
    866
  - Transponder
    866
  - U-Joint Remove / Install
    866
  - 1/4 Turn Left
    867
  - Lock Cylinder off the Ignition Lock
    867
  - Steering Wheel
    867
  - Gear
    868
  - Steering Gear Removal / Install
    868
  - Diagnosis and Testing - Outer Tie Rod End
    870
  - Linkage
    870
  - Outer Tie Rod End
    871
  - Tie Rod End
    871
  - Diagnosis and Testing - Pump Leakage
    872
  - Pump
    872
  - Standard Procedure - Power Steering Pump - Initial Operation
    872
  - Installation
    873
  - Power Steering Pump
    873
  - Removal
    873
  - Standard Procedure - Flushing Power Steering System
    873
  - Steering Pump Initial Operation
    873
  - Fluid Cooler Tube Removal
    874
  - Installation
    874
  - Power Steering Pump Fill and Bleed
    874
  - Installation - Pressure Hose
    875
  - Removal - Pressure Hose
    875
  - Removal - Return Hose from Gear to Cooler Tube
    875
  - Removal - Return Line from Pump to Cooler Tube
    875
Fluid

874
- Automatic Transmission - Nag1
  877
- Transmission Gear Ratios
  878
- Transmission Housing
  878
- Transmission Identification
  878
- Electrohydraulic Control Unit
  879
- Mechanical Section
  879
- NAG1 Automatic Transmission
  879
- Clutch Application
  880
- Emergency Running Function
  880
- Shift Groups
  880
- First Gear Powerflow
  881
- Front Planetary Gear Set
  881
- Rear Planetary Gear Set
  881
- Center Planetary Gear Set
  882
- Second Gear Powerflow
  883
- Third Gear Powerflow
  885
- Fourth Gear Powerflow
  887
- 1-2 Shift - First Gear Engaged
  893
- Shift Groups/ Shift Sequence
  893
- Shift Phase
  894
- Second Gear Engaged
  895
- Gear Shift N to D (1St Gear) - Engine Started
  896
- Activation Sequence
  897
- First Gear Engaged
  898
- Diagnosis and Testing - Automatic Transmission
  899
- Diagnosis and Testing - Preliminary
  899
- Vehicle Is Disabled
  899
- Vehicle Is Drivable
  899
- Drain Transmission
  903
- Remove Propeller Shaft and Heat Shield
  903
- Remove the Fill Tube
  903
- Standard Procedure - Aluminum Thread Repair
  903
- Remove Cable Support
  904
- Remove Cooler Line Supports
  904
- Remove Driver’s Side Cooler Line
  904
- Remove Transmission Electrical Connector and Cooler Line
  904
- Lower Steering Gear
  905
- Remove Shift Cable from Transmission
  905
- Remove Torque Converter Access Cover
  905
- Remove Torque Converter Bolts
  905
- Checking Input Shaft End Play
  906
- Remove Torque Converter
  906
- Support Transmission and Remove Bolts
  906
- Position Remover 9082 on Bearing
  907
- Remove Electrohydraulic Unit
  907
- Remove Rear Output Shaft Retaining Ring
  907
- Remove Output Shaft Bearing
  908
- Slide Remover 9082 Collar Downward
  908
- Remove K1, K2, and K3 Clutches
  909
- Remove Holding Clutch B1 and Oil Pump
  910
- Install B2, B3, and Parking Gear
  911
- Remove B2, B3, and Parking Gear
  911
- Check K1 Feed Hole
  912
- Measure B3 Clutch Clearance
  912
- Install Holding Clutch B1 and Oil Pump
  913
- Install New Oil Pump Seals
  913
- Install K1, K2, and K3 Clutches
  914
- Measure from Transmission Housing to Park Gear
  914
- Install Output Shaft Bearing
  915
- Install Rear Output Shaft Retaining Ring
  915
- Align Staking Tool 9078
  916
- Install Output Shaft Seal
  916
- Stake Output Shaft Nut
  916
- Install Electrohydraulic Unit
  917
- Install Torque Converter
  917
- Torque Converter Installation Depth
  917
- Position Driveplate as Shown
  918
- Position Torque Converter as Shown
  918
- Support Transmission and Install Bolts
  918
- Install Steering Gear
  919
- Install Torque Converter Access Cover
  919
- Install Torque Converter Bolts
  919
- Install Cable Support
  920
- Install Cooler Line Supports
  920
- Install Shift Cable Onto Transmission
  920
- Install Transmission Electrical Connector and Cooler Line
  920
- Install Driver’s Side Cooler Line
  921
- Install Propeller Shaft and Heat Shield
  921
- Install the Fill Tube
  921
- Install the Oil Drain Plug
  922
- Schematics and Diagrams
  923
- Hydraulic Flow in Reverse - Failsafe
  924
- Hydraulic Flow in Reverse
  925
- Hydraulic Flow in Neutral - Default
  926
- Hydraulic Flow in Neutral to Drive Transition
  928
- Hydraulic Flow in Drive - Failsafe
  929
- Hydraulic Flow in Drive - First Gear
  930
- Hydraulic Flow in Drive - First to Second Gear Transition
  931
- Hydraulic Flow in Drive - Second Gear
  932
- Hydraulic Flow in Drive - Second to Third Gear Transition
  933
- Hydraulic Flow in Drive - Third Gear
  934
- Hydraulic Flow in Drive - Third to Fourth Gear Transition
  935
- Hydraulic Flow in Drive - Fourth Gear
  936
- Hydraulic Flow in Drive - Fourth to Fifth Gear Transition
  937
- Hydraulic Flow in Drive - Fifth Gear
  938
- Hydraulic Flow in Drive - Fifth Gear - Emcc
  939
- Hydraulic Flow in Drive - Fifth to Fourth Gear Transition
  940
- Hydraulic Flow in Drive - Fourth to Third Gear Transition
  941
- Hydraulic Flow in Drive - Third to Second Gear Transition
  942
- Hydraulic Flow in Drive - Second to First Gear Transition
  943
- Gear Ratios
  944
- Specifications - Nag1 Automatic Transmission
  944
- Driving Clutches
  948
- Driving Clutch K1 Components
  951
- Driving Clutch K1 Stack-Up
  952
- Driving Clutch K2
  952
- Measure K1 Clutch Clearance
  952
- Driving Clutch K2 Components
  953
- Compress K2 Clutch Spring
  954
- Driving Clutch K2 Stack-Up
  956
- Driving Clutch K3
  956
- Measure K2 Clutch Clearance
  956
- Driving Clutch K3 Components
  957
- Electrical Control Unit
  958
- Electrohydraulic Unit
  958
- Hydraulic Control Unit
  958
- Working Pressure (Operating Pressure) (P-A)
  958
- Modulating Pressure (P-Mod)
  959
- Regulating Valve Pressure (P-RV)
  959
- Shift Pressure (P-S)
  959
- Shift Valve Pressure (P-SV)
  959
- Command Valve
  960
- Holding Pressure Shift Valve
  960
- Overlap Regulating Valve
  960
- Working Pressure Regulating Valve
  960
- Lubrication Pressure Regulating Valve
  962
- Shift Pressure Shift Valve
  962
- Regulating Valve Pressure Regulating Valve
  963
- Shift Pressure Regulating Valve
  963
- Shift Valve Pressure Regulating Valve
  963
- Torque Converter Lockup Clutch Regulating Valve
  964
- Working Pressure Regulating Valve (Operating Pressure)
  964
- Shift Valve Holding Pressure
  965
- Remove Heat Shield
  968
- Remove Wiring Connector Plug
  968
- Electrical Unit Components
  969
- Shift Plate Components
  969
- Shift Valve Group Locations
  969
- Check Balls and Strainer Location
  970
- Solenoid Valve Strainer Locations
  970
- Valve Body Components
  971
- Pressure Feed Valve Location
  972
- Valve Housing Components
  972
- Diagnosis and Testing - Causes of Burnt Fluid
  978
- Diagnosis and Testing - Effects of Incorrect Fluid Level
  978
- Diagnosis and Testing - Fluid Contamination
  978
- Standard Procedure - Check Oil Level
  978
- NAG1 Transmission Fill Graph
  979
- Standard Procedure - Transmission Fill
  979
- Dipstick Tube Cap Components
  980
- Fluid/Filter Service Points
  980
- Remove Dipstick Tube Cap Lock
  980
- Standard Procedure - Fluid/Filter Service
  980
- Freewheeling Clutch
  981
- Freewheeling Clutch F2
  982
- Freewheeling Clutch F2 Anti-Friction Bearing
  983
- Gearshift Cable
  985
- Remove Bottom Section of Center Instrument Panel
  985
- Remove Top Section of Center Instrument Panel
  985
- Holding Clutches
  987
- B2 Clutch Stack-Up
  995
- B2 Piston and Piston Guide Ring
  995
- Input Speed Sensors
  995
- Measure B2 Clutch Clearance
  995
- Shift Mechanism
  1009
- Torque Converter
  1017
- Diagnosis and Testing - Tire and Wheel Runout
  1025
- Tires/Wheels
  1025
- Lateral Runout
  1026
- Radial Runout
  1026
- Standard Procedure - Match Mounting
  1026
- First Measurement on Tire
  1027
- Remount Tire 180 Degrees
  1027
- Standard Procedure - Tire and Wheel Balance
  1027
- Dynamic Unbalance & Balance
  1028
- Static Unbalance & Balance
  1028
- Standard Procedure - Tire Rotation
  1029
- Description - Radial – Ply Tires
  1030
- Description - Tires
  1030
- Tire Chains
  1030
- Tire Identification
  1030
- Description - Replacement Tires
  1031
- Description - Tire Inflation Pressures
  1031
- Over Inflation Wear
  1031
- Under Inflation Wear
  1031
- Diagnosis and Testing - Pressure Gauges
  1032
- Diagnosis and Testing - Tire Noise or Vibration
  1032
- Diagnosis and Testing - Tire Wear Patterns
  1032
- Diagnosis and Testing - Tread Wear Indicators
  1032
- Vehicle Lead Diagnosis and Correction Chart
  1033
- Spare Tire Carrier
  1034
- Standard Procedure - Repairing Leaks
  1034
- Tire Repair Area
  1034
- Safety Rim
  1035
- Standard Procedure - Wheel Replacement
  1035
- Wheel Inspection
  1035
- Wheels
  1035
- (Drw) Wheel Cone Washers
  1036
- Dual Rear Wheel
  1036
- Standard Procedure - Dual Rear Wheel Installation
  1036
- Wheel Ring Flange Cone Washers
  1036
- Front Tire (Drw)
  1037
- Wheel Removal / Installation
  1037
- Body
  1039
- Diagnosis and Testing - Water Leaks
  1039
- Mirror Inspection Method
  1040
- Visual Inspection before Water Leak Tests
  1040
- Water Leak Detection
  1040
- Water Leak Tests
  1040
- Possible Cause of Wind Noise
  1041
- Road Testing Wind Noise
  1041
- Safety Precaution and Warnings
  1041
- Standard Procedure - Plastic Body Panel Repair
  1041
- Rigid, Semi-Rigid, and Flexible Plastic Parts Types
  1042
- Panel Reinforcement
  1044
- Panel Sectioning
  1044
- Softened Edges
  1044
- Panel Patch Fabrications
  1045
- Panel Surface Preparation
  1045
- Patching Panels
  1045
- Visual Inspection
  1045
- Damaged Panel Cutout and Patch
  1046
- Fabricated Panel
  1046
- Panel Patch Installation
  1046
- Secure Support Squares to Body Panel
  1046
- Apply Adhesive to Support Squares
  1047
- Grind Surface
  1047
- Install Screws
  1047
- Position Patch in Cutout and Align
  1047
- Cover Gaps with Mesh
  1048
- Cover Mesh with Adhesive
  1048
- Patched Panel Surfacing
  1048
- Standard Procedure - Buzz, Squeak & Rattle
  1048
- Buzz, Squeak & Rattle Kit
  1049
- Door - Front
  1051
- Front Door Check - Body
  1051
- Front Door Check - Door
  1051
- Electrical Connectors
  1052
- Front Door
  1052
- Door Glass
  1053
- Front Door Glass
  1053
- Glass Support
  1053
- Exterior Handle
  1054
- Exterior Handle Installation
  1054
- Latch Levers
  1054
- Latch/Handle Fasteners
  1054
- Hinge
  1055
- Front Door Latch
  1056
- Latch
  1056
- Latch Striker
  1056
- Lock Cylinder
  1056
- Trim Panel
  1057
- Trim Panel Fasteners
  1057
- Trim Panel Handle
  1057
- Control Cable
  1058
- Manual Regulator Assembly
  1058
- Window Regulator - Power
  1058
- Doors - Rear
  1062
- Check Strap
  1063
- Door Hinges
  1063
- Right Door
  1064
- Left Door
  1065
- Doors - Sliding
  1074
- Center Roller Arm
  1075
- Inside Handle Actuator
  1075
- Upper Roller Arm
  1075
- Lower Roller Arm
  1076
- Sliding Door Center Track
  1076
- Sliding Door Lower Roller Arm
  1076
- Sliding Door Scuff Pad
  1076
- Latch / Lock Control
  1077
- Lock Assembly Fasteners
  1077
- Sliding Door
  1077
- Lock Assembly
  1078
- Rear Latch
  1078
- Rear Latch Striker
  1079
- Sliding Door Assembly
  1080
- Hood
  1088
- Latch Release Cable
  1089
- Latch Release Handle
  1090
- Safety Latch
  1090
- Cluster Bezel
  1091
- Instrument Panel
  1091
- Accessory Switch Bezel
  1092
- Ash Receiver
  1093
- Cup Holder
  1093
- Instrument Panel Center Bezel
  1093
- Cup Holder Bottom
  1094
- Glove Box
  1094
- Hvac Control Module
  1095
- Instrument Panel Assembly
  1095
- Power Distribution Center Cover
  1095
- Passenger Side Air Nozzle Cover
  1096
- Power Distribution Center Connectors
  1096
- Center Vent Hose
  1097
- Instrument Panel Top Cover
  1097
- Protective Mat
  1097
- Side Covers & Nozzles
  1097
- Brake Pedal Spring
  1098
- Ignition Transponder
  1098
- Instrument Panel Fasteners
  1098
- Alignment Cutout
  1099
- Top Cover - Cluster
  1100
- Top Cover - Tray
  1101
- A-Pillar Trim
  1105
- Interior
  1105
- Assist Handle
  1106
- B-Pillar Trim
  1106
- Bulkhead Trim Panel
  1107
- Cargo/Passenger Van - Front
  1107
- Carpets and Floor Mats
  1107
- Passenger Van - Rear
  1107
- Cowl Trim
  1108
- D-Pillar Trim
  1108
- Headliner
  1108
- Passenger Van
  1109
- Quarter Trim Panel
  1109
- Rear View Mirror
  1110
- Stepwell Scuff Pads
  1110
- Sun Visor
  1111
- Basecoat/Clearcoat Finish
  1112
- Paint
  1112
- Paint Touch-Up
  1112
- Finesse Sanding/Buffing & Polish
  1113
- Standard Procedure - Paint Touch-Up
  1113
- Armrest
  1114
- Headrest
  1114
- Seats
  1114
- Seat - Front
  1115
- Seat Back - Front
  1115
- Comfort Seat Cushion
  1116
- Seat Adjusters - Front
  1116
- Seat Cushion - Front
  1116
- Standard Seat Cushion
  1116
- Rear Seat Back Shield
  1117
- Seat - Rear
  1117
- Three Passenger Bench
  1117
- Two Passenger Bench
  1117
- Seat Back Cushion/Cover - Rear
  1118
- Seat Cushion/Cover - Rear
  1118
- Backlite - Bulkhead Trim Panel
  1119
- Glass & Weatherstrip Seal Installation
  1119
- Quarter Window
  1119
- Stationary Glass
  1119
- Windshield
  1120
- Windshield Safety Precautions
  1120
- Adhesive Separation
  1121
- Instrument Panel Seal
  1121
- Windshield Seal
  1121
- Windshield Adhesive Preparation
  1122
- Windshield Positioning
  1122
- Windshield Primer
  1122
- Windshield Seal Installation
  1122
- Windshield Adhesive Application
  1123
- Windshield Installation
  1123
- Windshield Opening Preparation
  1123
- Windshield Opening Primer
  1123
- Windshield Adhesive Overlap
  1124
- Door Opening Seals
  1125
- Front Door Inner Belt Weatherstrip
  1125
- Front Door Outer Belt Weatherstrip
  1125
- Weatherstrip/Seals
  1125
- Body Structure
  1126
- Gap & Flush Dimensions Index
  1126
- Gap and Flush
  1126
- Rear Door
  1127
- Opening Dimensions
  1128
- Description - Cooling System Requirements
  1129
- Description - Heater and Air Conditioner
  1129
- Heating & Air Conditioning
  1129
- Heater Booster
  1130
- Heater Housing
  1130
- Operation - Heater and Air Conditioner
  1130
- Diagnosis and Testing - A/C Performance Test
  1131
- Diagnosis and Testing - Function Test
  1131
- Diagnosis and Testing - Heater Performance
  1132
- Maximum Heater Output
  1132
- Temperature Reference Chart
  1132
- A/C Compressor Clutch
  1136
- Controls - Front
  1136
- Compressor Clutch — Typical
  1137
- Compressor Shaft Bolt and Clutch Plate
  1137
- Standard Procedure - Compressor Clutch Air Gap
  1137
- Standard Procedure - Compressor Clutch Break-In
  1137
- Clutch Coil Snap Ring
  1138
- Clutch Plate and Shim(S)
  1138
- Inspection - Compressor Clutch/Coil
  1138
- Pulley Snap Ring
  1138
- Pulley Assembly Install
  1139
- A/C Compressor Clutch Coil
  1140
- A/C Heater Control
  1140
- Diagnosis and Testing - Compressor Clutch Coil
  1140
- A/C Pressure Transducer
  1141
- Diagnosis and Testing - A/C Pressure Transducer
  1141
- A/C Pressure Transducer Voltage
  1142
- Blower Motor Switch
  1150
- Controls - Rear
  1150
- Blower Motor Relay
  1151
- Control Module
  1152
- Rear A/C Control Module
  1153
- Rear Evaporator Panel
  1153
- Rear Roof Duct Panel
  1153
- Rear Evaporator Temperature Sensor
  1154
- Solenoid Valve
  1155
- Temperature Control
  1157
- Air Filter
  1159
- Air Outlets
  1159
- Distribution - Front
  1159
- Blower Motor
  1160
- Instrument Panel Air Outlets
  1160
- Defroster Ducts
  1161
- Floor Distribution Ducts
  1161
- Hvac Housing
  1162
- Distribution - Rear
  1167
- Rear A/C Housing
  1168
- Plumbing
  1171
- Heater Core
  1185
- Water Valve
  1195
- Cabin Heater
  1200
- Fuel Line
  1203
- Heater Unit
  1205
- Emissions Control
  1209
- Exhaust Gas Recirculation
  1209

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